基于刚度缩聚和局部更新的薄壁件铣削力所致误差高效预测与实时补偿

doi:10.3901/JME.2025.17.331

机械工程学报 ›› 2025, Vol. 61 ›› Issue (17): 331-342.doi: 10.3901/JME.2025.17.331

• 制造工艺与装备 • 上一篇

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基于刚度缩聚和局部更新的薄壁件铣削力所致误差高效预测与实时补偿

葛广言¹, 肖域坤¹, 吕军^1,2, 杜正春¹

1. 上海交通大学机械与动力工程学院上海 200240;
2. 通用技术集团机床工程研究院有限公司大连分公司大连 116620

收稿日期:2024-09-13 修回日期:2025-01-12 发布日期:2025-10-24
作者简介:葛广言，男，1994年出生，博士。主要研究方向为薄壁件铣削加工误差检测、建模与实时补偿。E-mail：geguangyan@sjtu.edu.cn;杜正春(通信作者)，男，1973年出生，博士，副教授，博士研究生导师。主要研究方向为数控机床几何误差、热误差与力致误差的综合检测、建模与实时补偿。E-mail：zcdu@sjtu.edu.cn
基金资助:
国家自然科学基金(U22B2086, 52375504)和通用技术集团科技重大专项(GTZD-2022-014)资助项目。

Efficient Prediction and Real-time Compensation of Milling Force-induced Error in Thin-walled Parts Based on Stiffness Reduction and Local Update

GE Guangyan¹, XIAO Yukun¹, Lü Jun^1,2, DU Zhengchun¹

1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240;
2. Genertec Machine Tool Engineering Research Institute Co., Ltd., Dalian Company, Dalian 116620

Received:2024-09-13 Revised:2025-01-12 Published:2025-10-24

摘要/Abstract

摘要： 航空薄壁件具有结构复杂、刚度弱以及材料去除率高等特性，在铣削力的作用下极易产生加工误差。工艺优化和有限元技术的发展为解决此问题提供了有效手段，但仍存在经济成本高和计算耗时长等问题，因此提出了一种薄壁件铣削力所致误差高效预测与实时补偿方法。首先，针对有限元法在考虑切除效应时计算量大的问题，建立了基于刚度缩聚和局部更新的力致误差高效预测模型。进而，针对刀具—工件弹性变形导致实际与理想补偿量存在偏差的问题，提出了基于迭代系数的误差补偿量修正计算方法。最后，以薄壁叶片为对象开展了补偿加工实验。实验结果表明，叶片误差补偿值的预测时间相比于生死单元法降低了45.9%，加工误差相比于无补偿工况降低了58.3%，有效提高了其加工误差及补偿值的计算效率和精度。

关键词: 薄壁件, 铣削加工, 误差建模, 刚度矩阵, 实时补偿

Abstract: Aerospace thin-walled parts are prone to machining errors under the action of milling forces due to their complex structures, weak stiffness, and high material removal rates. Machining process optimization and the finite element method provide effective means to solve this problem, but issues such as high economic costs and long computation time still exist. Therefore, an efficient prediction and real-time compensation method for milling force-induced errors in thin-walled parts is proposed. Firstly, to address the large computational load of the finite element method when considering the material removal effect, an efficient prediction method based on stiffness reduction and local update is established. Furthermore, an error compensation value calculation method based on iterative coefficients is proposed to decrease the deviation between the actual and ideal compensation amounts caused by tool-workpiece elastic deformation. Finally, a thin-walled blade milling experiment is carried out. The experiment results revealed that the prediction time for compensation value is decreased by 45.9% compared to finite element methods, and the machining error is reduced by 58.3% after compensation, effectively improving its computation efficiency and machining accuracy.

Key words: thin-walled parts, milling, error modelling, stiffness matrix, real-time compensation

中图分类号:

TH164

葛广言, 肖域坤, 吕军, 杜正春. 基于刚度缩聚和局部更新的薄壁件铣削力所致误差高效预测与实时补偿[J]. 机械工程学报, 2025, 61(17): 331-342.

GE Guangyan, XIAO Yukun, Lü Jun, DU Zhengchun. Efficient Prediction and Real-time Compensation of Milling Force-induced Error in Thin-walled Parts Based on Stiffness Reduction and Local Update[J]. Journal of Mechanical Engineering, 2025, 61(17): 331-342.

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基于刚度缩聚和局部更新的薄壁件铣削力所致误差高效预测与实时补偿

Efficient Prediction and Real-time Compensation of Milling Force-induced Error in Thin-walled Parts Based on Stiffness Reduction and Local Update

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